Machine for and a method of manufacturing a laminate particularly adapted for bedding, padding, and upholstering

ABSTRACT

A method of manufacturing a laminate particularly adapted for bedding, padding upholstering and like applications by feeding an indeterminate length of a first material along a predetermined first path of travel from a source of the first material to a downstream assembly area. Feeding an indeterminate length of second material along a predetermined second path of travel from a source of the second material to the downstream assembly area. Depositing a multiplicity of substantially yieldable cushioning materials upon an upper surface of one of the first and second indeterminate lengths of material during the feeding thereof between the respective sources and the assembly area. Thereafter, sandwiching the cushioning materials between the indeterminate lengths of first and second materials to form a laminate therefrom, and rolling the laminate into a roll. The cushioning materials are foam latex and/or down and the first and second lengths of material are polyester fiber material and/or convoluted foam.

BACKGROUND OF THE INVENTION

A mattress normally includes a coil spring unit defined by a pluralityof interconnected coil springs which are united to each other and toupper and lower polygonal frame wires which impart a generallyrectangular configuration to the coil spring unit. An upper or topmattress pad and a lower or bottom mattress pad, each formed of multiplelayers or plies of materials stitched together, and a like narrowperipheral mattress pad, also formed of multiple plies or layers, areassembled to entirely encapsulate the coil spring unit and form themattress.

The top, bottom and peripheral mattress pads are each formed as alaminate which might, for example, include a backing material layer, afoam material layer, a fiber material layer and a ticking layer, allstitched together by stitching of a conventional “quilt” pattern ordesign. The materials of the latter layers, the thicknesses thereof,etc. all contribute to such characteristics as softness, breathability,wear, etc. However, irrespective of the particular layers, it isimportant that the upper mattress pad and the lower mattress pad aremanufactured as inexpensively as possible, yet provide the best mattresscharacteristics possible at the lowest equitable cost over the longestmattress life possible.

A typical conventional mattress corresponding to the mattress justdescribed is disclosed in U.S. Pat. No. 5,317,768 granted on Jun. 7,1994. The patent discloses a spring component and at least a top surfacecomponent formed as a laminate with the outer layer being the ticking orcover fabric, the next inboard layer being a fiber layer, the thirdlayer being a convoluted foam layer, and the innermost fourth layerbeing a cotton layer with associated stitching holding all four of theselayers together to form a quilted multi-ply mattress pad. The thicknessof the fiber layer and the thickness of the convoluted foam layer aresaid to be matters of design choice, though specific examples of weightper square foot of the polyester fiber and the height of the convolutedfoam layer are specified as being illustrative. However, it is generallyconceded that the best mattresses providing the most comfort are thosewhich include an appreciably thick layer of convoluted foam. However,foam material, particularly latex (natural rubber) foam is extremelyexpensive and, therefore, appreciably thick convoluted latex foam layersare found most exclusively in higher end, more expensive mattresses. Itwould be highly desirable to increase the latex foam content in lowerend mattresses (less expensive) if costs could be maintained relativelylow during the manufacture thereof such that as an end result virtuallyall qualities of the mattress are appreciably increased at a moderate orlow increase in cost at both the wholesale and retail levels.

SUMMARY OF THE INVENTION

In keeping with the foregoing, it is a primary object of the presentinvention to provide as an end product a novel mattress which includes aconventional coil spring unit and at least a top or upper mattress padformed of multiple plies or layers including at least one fiber layerand one convoluted foam latex layer having conventional peaks andvalleys with the valleys being each substantially filled with amultiplicity of relatively inexpensive, small, random sized, foam latexpieces/materials which might otherwise be discarded as scrap, yetpossess all of the highly desirable characteristics of a solid latexfoam layer. Since the relatively small pieces of foam latex areentrapped in the valleys during lamination, as will be described morespecifically herein, the manufacture of such an upper and/or lowermulti-ply mattress pad is relatively inexpensive and, thus, can beutilized to enhance all grades of conventional mattresses now beingproduced, sold and used throughout the world.

In further accordance with the present invention, such relatively smallrandom sized pieces of latex foam material are also preferablysandwiched between two layers of fiber material, such as conventionalpolyester fiber, to form an upper mattress pad, a lower mattress padand/or a peripheral mattress pad formed of three plies, namely, apolyester fiber ply or layer, a layer of latex foam pieces and anotherpolyester fiber ply or layer. As thus far described and as opposed tothe first laminated mattress pad herein described, the small individualpieces of latex foam (hereinafter termed “latex”) would tend to shift ormove when in use as part of a mattress, unless otherwise provided for,as is the case of the present invention in which the two polyesterlayers are stitched together by a conventional quilting machine whichnot only secures the layers together as a unit, but the stitchingconfines or limits the movement or “migration” of the latex when used,for example, as the upper and/or lower mattress pads of a mattress.Thus, conventional stitching of the quilting process not only functionsto maintain the two polyester fiber layers (or any other additionallayers) united, but the stitching additionally precludes undesired latexmigration/shifting which essentially maintains uniform latex thicknessand results in a very comfortable yet inexpensive mattress available atlow and moderate prices while providing moderate to high quality comfortand softness absent localized “hard” spots, as might otherwise occurwith undesired latex migration.

In keeping with the foregoing, the last described mattress pad is formedby a, novel laminating machine of the present invention which providesrespective first and second means for rotatably supporting first andsecond rolls of polyester fiber material with an upper surface of alayer or web of the first roll being fed beneath a trough from whichlatex/latex pieces are fed. Downstream of the trough a second layer orweb of the second roll of polyester fiber material is overlayed upon thepieces of latex at an assembly area during the continuous travel of thepolyester fiber layers toward a roll forming or winding station. Thethus formed laminate (polyester fiber layer/latex pieces/polyester fiberlayer) are then preferably wound into a roll of laminate/laminate roll,the laminate is cut upstream of the roll, and the laminate roll ispackaged and shipped to a mattress manufacturer for utilization in themanufacture of a mattress as described earlier herein. An area isprovided for storing packaging material, such as a roll of transparentpolymeric/copolymeric packaging material, adjacent the roll formingstation to use as the packaging material for the laminate roll.Obviously, the diameter of the laminate roll and its length will varydependent upon the thicknesses of the polyester fiber layers and theamount of latex sandwiched therebetween. No matter the length, width ordiameter of the laminate roll, preferably a flying shear or flyingcutter severs the laminate normal to the direction of travel in responseto automated or manual controls immediately upon completion of the rollpackaging operation.

Immediately upon effecting lamination at the lamination or assemblyarea, the longitudinal edges of the polyester fiber layers are subjectto an edge-binding operation which is preferably achieved throughspraying a fast drying adhesive therealong which virtually driesinstantaneously under normal temperature ranges found in factories, butheaters may be used, as necessary. The adhesive thus sprayed along thelongitudinal edges binds all edge-exposed latex pieces to each other andto the polyester fiber layers. Alternatively or additionally,compression edge rollers can be utilized downstream of the adhesivespray applicators, preferably spray guns, to bring the polyester layersinto intimate adhesive bonding contact, thereby further assuring thatthe latex/latex pieces cannot escape the laminate.

In lieu of immediately forming the laminate into a roll, cutting thelaminate, packaging the laminate roll and shipping the same to an enduser, the laminate may be fed directly into a quilting machine andconventionally quilted or stitched to not only provide unification ofthe layers and the attendant conventional “quilted” appearance ofmattresses, but to also prevent latex “migration.” Conventional quiltingmachines have multiple programmable stitching heads and in accordancewith the present invention, such stitching heads are programmed not onlyto provide an aesthetic quilt appearance, but to also create essentiallya multiplicity of relatively small “closed” pockets between thepolyester fiber layers defined by the threads of the stitching with thethreads or stitching of each “pocket” confining the latex therein andsubstantially preventing latex migration outwardly of each stitchedpocket. The simplest example of the latter is stitching the laminateprior to rolling or immediately upon being unrolled at a mattressfabricator by closely spaced rows of stitching normal and parallel tothe direction of travel of the laminate (rolling direction of thelaminate roll) to form substantially square or polygonal “closed”pockets, each being relatively “closed” by the stitching associatedtherewith. Though such “closed” pockets of stitching are desirable, thestitching need not define completely “closed” pockets, but the stitchinginstead might be configured such as to prevent excessive migration as,for example, closely adjacent parallel sinusoidal stitching eitherlengthwise or widthwise of the laminate which forms narrow sinusoidalchannels which essentially prevent latex migration by the very curvednature thereof and the relatively narrow width of each channel.

The trough which houses the latex preferably includes a tubularpolygonal rubber chute carrying at a lower end a latex proportioninggate having a plurality of proportioning openings therein through whichpass the latex for deposit upon the upper surface of the polyester fiberlayer being conveyed therebeneath. The openings in the gate or platevary in number, size, shape and orientation depending upon the range ofsizes of the particles of the latex being fed therethrough, the amountof latex which is to be deposited per square foot/yard (and thus theeventual height thereof) upon the upper surface of the underlyingpolyester fiber layer, the speed of production, etc. Gates varying inopening numbers, sizes, shapes and configurations are provided inaccordance with the invention for selective utilization to manufacturevirtually any and all end product characteristics, such as latex height,density, etc.

The rubber chute or the gate also carries spacers which engage the uppersurface of the polyester fiber layer passing therebeneath and assuresthat this upper surface is spaced at all times a minimum distance fromthe gate/plate openings. The minimum distance corresponds to the maximumheight of the layer of latex which is to be applied to the underlyingpolyester fiber layer. Since the underlying polyester fiber layer is incontinuous motion as it is conveyed toward the assembly/laminating area,its inherent resilience evokes up-and-down movement during theconveyance thereof which, if excessive in an upward direction, willcause the upper surface of the polyester fiber layer to move undesirablycloser to the gate openings resulting in the height of the latex beinglessened and lessened appreciably beyond that desired. Thus, bymaintaining the gate openings at a predetermined minimum distance fromthe upper surface of the underlying polyester fiber layer during itsmovement, the thickness/height of the latex is at all times maintainedat a uniform desired maximum height which in turn results in a laminateof uniform cross-sectional thickness throughout.

The trough also includes a pair of trough plates, one fixed and anotherwhich is adjustable, and between the two trough plates is a vane feedroll or roller which can be rotated at different speeds dependent uponthe desired rate of feed of the latex. Lower edges of the trough platesdefine a transverse slot which can be increased in size by moving theedge of the movable trough plate away from the fixed trough plate anddecreased in size by opposite motion for varying the rate of feed of thelatex in conjunction with the speed of rotation of the vane feed roll orvane feeder.

The laminating machine also includes a drive mechanism for the take-uproll or roll forming mechanism which is variably adjustable inrotational speed while shafts supporting the rolls of polyester fiberlayers or webs are under constant tension of a conventional adjustablebrake mechanism. The tension is relatively slight but sufficient tomaintain the upper surface of the polyester fiber layer passing beneaththe trough relatively horizontally disposed to prevent vertical motionand/or bowing during travel, and thereby assures maximum uniformity ofthe height of the latex deposited thereupon. Thus, by manually orautomatically adjusting the speed of rotation of the shaft upon whichthe laminate is being wound to form the laminate roll, the amount oflatex being deposited upon the upper surface of the underlying polyesterfiber layer can be further regulated in conjunction with the earliermentioned adjustable trough plate, adjustable vane feeder, and differentproportioning gates.

The laminating machine can also be utilized to form a multi-ply orlaminated mattress pad defined by a convoluted latex foam layer having arelatively flat surface and an opposite surface defining peaks andvalleys, latex particles housed within the valleys, and a polyesterfiber layer. The latter-described mattress pad is manufactured by thelaminating machine in the manner just described with the exception thatthe downstream roll of polyester fiber material is not utilized, and inlieu thereof a roll of convoluted latex foam is supported upon anassociated shaft and is drawn therefrom with its peaks and valleysrespectively pointing toward and opening toward the upper surface of theunderlying polyester fiber layer. In this fashion as the latex particlesdeposited upon the upper surface of the lower polyester fiber layer passbeneath and are united with the convoluted latex foam layer, the latexparticles are entrapped/encapsulated within the valleys or “pockets” ofthe convoluted latex foam layer. The laminate thus formed is rolled intoa laminate roll and/or stitched by a conventional quilting machine,though the quilt pattern need not provide stitching “pockets,” as in thecase of the polyester fiber layer/foam latex particles/polyester fiberlayer laminate, because the valleys are the “pockets” and prevent latexmigration.

With the above and other objects in view that will hereinafter appear,the nature of the invention will be more clearly understood by referenceto the following detailed description, the appended claims and theseveral views illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a novel laminating machine constructedin accordance with this invention, and illustrates foam latex particlesbeing deposited upon an upper surface of a polyester fiber layer or webbeing drawn from a roll, and another polyester fiber layer being appliedthereto forming a laminate which is formed into a laminate roll and ispackaged for delivery to a mattress manufacturer.

FIG. 2 is an enlarged cross-sectional view taken generally along line2—2 of FIG. 5 through a trough which houses the foam latex particles,and illustrates a fixed and a movable trough plate, a vane feeder, and arubber chute through which the foam latex pieces moves incident to beingdeposited upon an upper surface of the polyester fiber layer passingbeneath the trough.

FIG. 3 is an enlarged fragmentary cross-sectional view of the movableand fixed trough plates and the vane feeder therebetween, andillustrates one of many different relative positions to achieve desiredlatex feed therethrough.

FIG. 4 is a fragmentary enlarged perspective view similar to FIG. 3, andillustrates another relative position of the fixed and movable troughplates and the vane feeder which alters the relative size of thetransverse slot, as compared to FIG. 3, and thereby varies the rate oflatex feed.

FIG. 5 is an enlarged fragmentary cross-sectional view taken generallyalong line 5—5 of FIG. 1, and illustrates a drive for the vane feederand a portion of a linkage for varying the adjusted position of themovable trough plate.

FIG. 6 is a fragmentary top perspective view looking downwardly into thetrough, and illustrates a removable trough end plate partially removedto provide access to journals and bearings associated with the movabletrough plate and the vane feeder.

FIG. 7 is a fragmentary top perspective view of the left side of thetrough, as viewed in FIG. 1, and illustrates a handle and a screw threadreceived in an internally threaded sleeve of the linkage for adjustingthe position of the movable trough plate.

FIG. 8 is a bottom perspective view of a spacer assembly, andillustrates a spacer frame carrying three convex spacer rods.

FIG. 9 is a bottom perspective view of a proportional feed gate or feedplate, and illustrates a plurality of substantially identically shapedrectangular openings thereof.

FIG. 10 is a fragmentary bottom perspective view of another proportionalfeed gate or feed plate, and illustrates openings of two different sizesformed therein.

FIG. 11 is a bottom perspective view of another proportional feed gateor feed plate, and illustrates a further group of feed openings formedtherein.

FIG. 12 is a fragmentary longitudinal cross-sectional view takengenerally, along line 12—12 of FIG. 1, and illustrates the proportionalfeed gate of FIG. 9 and the spacer assembly of FIG. 8 removably securedto a lower terminal edge of the rubber chute with the convex spacer rodstouching an upper surface of the underlying polyester fiber layer.

FIG. 13 is a fragmentary longitudinal cross-sectional view similar toFIG. 12, and illustrates a roll of convoluted foam latex in lieu of thedownstream roll of polyester material of FIG. 12.

FIG. 14 is an enlarged fragmentary longitudinal cross-sectional view ofthe lamination of FIG. 13, and illustrates a multiplicity of randomlysized latex particles/pieces substantially filling downwardly openingvalleys or pockets of the convoluted latex foam layer.

FIG. 15, which appears on the sheet of drawing containing FIG. 7, is afragmentary top perspective view of a modification of the laminationmachine of FIG. 1, and illustrates the polyester fiber layer/latex foampieces/polyester fiber layer laminate being fed into a conventionalquilting machine and both transverse and longitudinal sinusoidalstitching forming substantially closed pockets to prevent latexmigration.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A novel machine for manufacturing a laminate particularly adapted foruse in bedding (mattresses), padding, upholstering and like applicationsis fully illustrated in FIG. 1 of the drawings and is generallydesignated by the reference numeral 10.

The laminate manufacturing machine or laminating machine 10 includesfirst means 11 for feeding an indeterminate length or layer L1 of firstmaterial M1, such as polyester fiber, from a roll R1 thereof along afirst predetermined path of travel P1 (FIGS. 1 and 12) which is fromleft-to-right in each of the two latter figures toward a downstreamassembly or laminating area A (FIG. 1).

Second means 12 are provided for feeding another indeterminate length orlayer L2 of second material M2 of polyester fiber from a roll R2 along apredetermined second path of travel P2 (FIG. 1). The paths of travel P1,P2 are for the most part substantially in the same direction and aresubstantially horizontally disposed.

Means 13 are provided for depositing a multiplicity of substantiallyyieldable cushioning materials L, such as pieces of foam latex of randomsizes, upon an upper surface Us of the polyester fiber layer L1 of apredetermined height H (FIG. 12) in a manner to be described more fullyhereinafter. The pieces of foam latex L are deposited upon the uppersurface Us of the polyester fiber layer L1 upstream of the roll R2 ofthe polyester fiber layer L2, as is evident from FIGS. 1 and 12 of thedrawings. The latex L is deposited upon the upper surface Us of thepolyester fiber layer L1 in varying amounts depending upon such factorsas the quality of the latex L, whether the mattress to be formedtherefrom will be low, moderate or high priced, etc., but for the mostpart the latex L deposited upon the layer L1 will range between0.15-0.30 pound per square yard of the layer L1. The range can, ofcourse, be lessened for less expensive end product production andincreased for higher priced end products, as, for example, the depositedlatex L might be between 0.10-0.50 pounds per square yard. Latex anddown, admixed 50%/50% can also be used as the layer L in the preferablerange of 0.15-0.30 pound per square yard and up to the broader 0.10-0.50pound per square yard range.

Means 15 in the form of identical adhesive spraying mechanisms arelocated an along opposite longitudinal edges (unnumbered) of the layersL1, L2 and the eventually formed laminate Lm which direct an adhesivespray S therealong to edge-bind/edge-bond the longitudinal edges of thelayers L1, L2 to each other.

Means 16 in the form of an upper roller 17 and a lower roller 18temporarily compress the laminate Lm during the passage therebetween toeffectively close the longitudinal edges of the layers L1, L2 andpreclude the latex L from being dislodged outwardly of the layers L1,L2.

Means 20 are provided for rolling the laminate Lm into a laminate rollLr.

When the laminate roll Lr is of a desired size, an operator or anappropriate conventional microcontroller Mc, such as Motorollamicrocontroller C68HC05J2P, which contains a variety of input/outputpins that are programmable to effect a multiplicity of functionsincluding that of appropriately controlling cutting means 22, such as aconventional flying shear or flying cutter, which cuts the laminate Lmnormal to the direction P1, P2 thereby freeing the laminate roll Lr forsubsequent packaging and shipment.

Means 24 support a roll R3 of packaging material, such as a roll ofpolyethylene P, above the roll of laminate Lr. The polyethylene materialP is simply drawn from the roll R3, wound about the roll of laminate Lr,severed from the roll R3, and appropriate edge-to-edge sealed to encase,protect, and package the laminate roll Lr therein for subsequentshipping to a mattress manufacturer or the like.

The first feeding means or first feeding mechanism 11 includes oppositeuprights 30 of which only one is illustrated in FIG. 1 and between whichis rotatably supported a shaft 31 which is in intimate frictionalengagement with the innermost convolution of the roll R1. A conventionaladjustable brake 32 can be adjusted by a worker or by themicrocontroller Mc to maintain desired drag on the layer L1 as it isdrawn from the roll R1 by the roll forming mechanism 20 in a manner tobe described more fully hereinafter. The brake or brake means 32, nomatter the specifics of the construction thereof, is relativelyconventional and is designed simply to assure that sufficient pull ortension is applied to the layer L1 to maintain the same substantiallyhorizontal with little bow therein during movement along the path P1.The tension is augmented by a top roller 33 spring biased downwardlywhich spans the width of the layer L1, the purpose of which is totake-up any minute “slack” which might otherwise occur in the layer L1during its movement along the path of travel P1.

The lower layer L1 is preferably freely fed absent lower support fromthe point of take-off from the roll R1 until it enters between therollers 17, 18. However, a lower surface Ls (FIG. 12) of the layer L1may be supported upon an upper surface (unnumbered) of a relativelysmooth glide plate Gp formed of material having an extremely lowco-efficient of friction or coated with such material, such as syntheticfluorine-containing resins (Teflon®). In lieu of the guide plate Gp, aplurality of transverse conveyor rollers (not shown) may be utilized toassure that the upper surface Us of the layer L1 is at a fixed heightduring the passage thereof through the foam latex depositing means 13.

The latex depositing means 13 includes a trough 40 conventionallysupported by a frame F in transversely spanning relationship to thelayer L1. The trough 40 is defined by an upstream wall 41 and adownstream wall 42 which converge relative to each other in a downwarddirection. The walls 41 and 42 are welded to a side wall 43 and oppositethereto the walls 41, 42 are similarly welded to an outboard oppositeside wall 44 (FIGS. 5 and 6). A removable inboard side wall 45 (FIGS. 5and 6), when seated in its operative position (FIG. 5), covers andprotects housings and bearings of linkages and shafts to be describedmore fully hereinafter. This protects the housings, bearings and shafts,yet provides ready access thereto for repair or replacement by simplygripping and pulling the removable inboard side wall 45 upwardly fromthe position shown in FIG. 5 to that shown in FIG. 6.

Lowermost terminal edge portions 51, 52 (FIG. 2) of the converging walls41, 42, respectively, are generally in parallel relationship to eachother, and these collectively define with lower edge portions(unnumbered) of the end walls 43, 45 a transverse opening 60 above andextending entirely across the layer L1 as it passes therebeneath.

Housed within the trough 40 and extending substantially the entirelength of the transverse opening 60 are means 70 for cooperativelyadjustably varying the size of the transverse opening 60 and betweenwhich is located rotatable feed means 80 for regulating the passage ofthe latex L through the transverse opening 60.

The opening size adjusting means 70 include a fixed trough plate 71 anda movable trough plate 72 (FIGS. 2, 5 and 6). The fixed trough plate 71is welded along its entire length to the downstream wall 42 and to theside wall 43, but not to the removable inboard side wall 45. The movabletrough plate 72 is welded along its entire length to a shaft 73 which atthe end adjacent the removable inboard side wall 45 passes through aslot 47 thereof (FIG. 6). The shaft 43 passes through a bearing (notshown) of a bearing housing 74 (FIG. 6) and passes through an opening(not shown) in the outboard wall 44 (FIG. 7) beyond which it isconnected to a linkage 75 (FIG. 7). The opposite end of the shaft 73 isreceived in a bearing and a housing corresponding to the housing 74mounted adjacent the side wall 43 (not shown). The trough plate 72 canthereby pivot selectively and adjustably relative to the fixed troughplate 71 and the rotatable feed means 80 in the manner diagrammaticallydepicted in FIGS. 3 and 4 of the drawings to thereby vary the size ofthe transverse opening 60 to selectively vary the rate of feed of thelatex L therethrough under any one particular speed of rotation of therotatable feed means 80. In other words, though the rotatable feed means80 can be varied in its rotational speed, changes in the amount of latexL discharged through the transverse opening 60 can be altered by merelypivoting and changing the position of the pivotable trough plate 72relative to the rotating feed means 80 and the fixed trough plate 71.

The means or mechanism for varying the position of the trough plate 72includes trough plate adjusting means 90 (FIG. 7) in the form of athreaded screw 91 having an unthreaded end 92 journalled for rotation ina bearing (not shown) fixed to a housing wall 93 and carrying a handle94. An internally threaded sleeve 95 forms part of the linkage mechanism75 (FIGS. 5 and 7) and threadably receives therein the threaded shaft91. Links 96, 97 (FIG. 7) are pivotally connected to the sleeve 95 by apivot pin 98 while opposite ends of the links 96, 97 have fixed theretothe shaft 73, as by welding, of the trough plate 72. As is readilyapparent from FIG. 7 of the drawings, as the handle 94 of the troughplate adjusting means 90 is rotated in either of two directions, thethreaded shaft 91 will thread into or out of the sleeve 95 to pivot thelinks 96, 97 which in turn rotate the shaft 73 which in turn pivots themovable or pivotable trough plate 72 to achieve the selected variationin size of the transverse opening 60 (FIGS. 2 through 4).

The rotatable feed means 80, which also regulates the passage of thepieces of latex L through the transverse opening 60 through selectedspeeds of rotation, is defined by a rotatable vane feeder 81 having acentral cylindrical portion 82 and five equally arcuately spacedradially outwardly directed vanes 83 projecting therefrom. Thecylindrical central portion 82 is reduced in size at opposite endportions, and one such end portion 84 is illustrated in FIGS. 5 and 6 ofthe drawings projecting through a downwardly opening slot 48 of theremovable inboard side wall 45 and being journalled for rotation in abearing of a bearing housing 85 (FIG. 5) bolted to the outboard sidewall 44. A bearing housing (not shown) corresponding to the bearinghousing 85 secures the opposite reduced end (not shown) of thecylindrical portion 82 of the rotatable vane feeder 81 to the side wall43. The end portion 84 projects through an opening (unnumbered) in theoutboard side wall 44 (FIG. 5) and is driven by a conventionalright-angle drive 86 of an electric motor 87 which is controlled indirection of rotation and speed of rotation by the microcontroller Mc orone of several conventional manually operated adjustable electricswitches, such as a switch 89 (FIG. 1) fixed to the wall 93 of thetrough 40. As the speed of rotation of the rotatable vane feeder 80 isincreased, more latex L is fed through the transverse opening 60,irrespective of the size thereof, while a decrease in rotational speedof the rotatable vane feeder 80 effects the opposite result.

As the latex L descends vertically downwardly under the influence ofgravity through the transverse opening 60, it passes through and isguided by guide means 100 in the form of a rubber guide chute or sleevehaving a generally rectangular cross-sectional configuration, as viewedfrom above and below, and terminates in a lower polygonal terminal edgeportion 101 spaced the height H (FIG. 12) above the upper surface Us ofthe polyester fiber layer 1. The height H represents the maximum heightof the latex L that will under any circumstances be deposited atop theupper surface Us of the layer L1.

Spacer means 110 (FIG. 8) and latex feed proportioning means 120 (FIG.9) are each carried by the lower terminal edge portion 101 of the guidechute or sleeve 100.

The latex feed proportioning means 120 is a feed gate or feed plate of agenerally rectangular configuration having an upper flange 121 of apolygonal configuration whose internal size matches the exterior size ofthe terminal end portion 101 of the guide chute 100. Thus, the terminalend portion 101 of the guide chute 100 can be slipped into the upperflange 121 of the proportional feed gate 120 and secured thereto byfasteners, such as screws or clips 122 (FIGS. 12 and 13) passed throughopenings 119 of the upper flange 121. A plurality of like sizedgenerally rectangular identically spaced proportioning openings 123 areformed in the proportioning plate 120 and it is through theproportioning openings 123 that the latex L passes before beingdeposited upon the upper surface Us of the layer L1. Since the openings123 are substantially equally spaced and identically sized, they assurethat no matter the existence of any inconsistencies in content or volumeof the latex L falling through or accumulating in the chute 100,substantially equal amounts of latex L will fall through each opening123 to create a substantially uniform and consistent height H. Differentopenings 123′ (FIG. 10) and 123′ (FIG. 11) of respective proportionalfeed plates 120′, 120″ afford effective dispensing of latex L dependentupon differences in relative sizes of the pieces of latex L, the heightH which must be achieved, the speed of production, etc. In other words,if the pieces of latex L are of one size or a specific size range, theproportional feed gate 120 might be utilized to obtain a desired heightH, whereas should the pieces of latex L be of a different size, range ofsizes or consistency, the proportioning plate 120′ or the proportioningplate 120′ might be instead utilized. However, no matter the particularproportioning plate 120, 120′ or 120″ which is secured to the terminaledge portion 101 of the guide chute or sleeve 100, the selection thereofwill assure the exact height H and consistency of the latex pieces Ldeposited upon the polyester fiber layer L1 under all manufacturingprotocols, such as the speed of rotation of the laminate roll Lr, thespeed of rotation of the vane feeder 81, the size of the transverseopening 60, etc.

The spacing means 110 is a spacer assembly defined by a polygonal frame111 having a plurality of openings 112 therein matching the location ofthe openings 119, 119′, 119″ of the proportional feed plates 120, 120′,120″. The internal size of the frame 111 of the spacer assembly 110substantially matches the external size and configuration of the flanges121, 121′, 121″ of the respective proportional feed plates 120, 120′ and120″. The frame 111 can be telescoped upon and secured to the flanges121, 121′, 121″ and/or the terminal edge portion 101 of the chute 100 byutilizing conventional fasteners, such as the fasteners 122 (FIGS. 12and 13). Projecting downwardly from the frame 111 in a convex fashionare three relatively narrow spacer rods 125 which are parallel to thedirection of travel P1 and which contact the upper surface Us of thelayer L1 (FIG. 12) maintaining it at all times spaced the distance H,thus assuring no matter the vertical deflection or flexing of the layerL1 during its movement, the height H of the latex L deposited upon theupper surface Us will never be less than the height H. Though notillustrated, spacer assemblies corresponding to the spacer assembly 110can be provided as substitutes therefor with the curvature or the spacerbars 125 being lesser or greater than that shown to respectivelydecrease and increase the height H to achieve lesser or greater height Hthan that illustrated in FIG. 12. In lieu of additional spacing means,the spacing means 110 may be modified in the manner illustrated inphantom outline (dashed lines) in FIG. 8 which illustrates an increasein the overall height of the frame 111 with additional openings 112being also shown in phantom outline in vertical spaced relationship toeach other. There are three such vertical spaced openings shown in theframe 111, and depending upon which of these are utilized to fasten theframe 111 to the lower edge portion 101 of the chute 100, the distanceof the spacer bars 125 from the upper surface Us of the polyester fiberlayer L1 can be variably adjusted to occupy any one of three positionsthus assuring three different distances for the height H of the latex Ldeposited upon the upper surface Us of the polyester fiber layer L1.

The means or mechanisms 15 (FIG. 1) for edge-binding/edge-bonding thelayers L1, L2 to each other, along with the foam latex pieces Lsandwiched therebetween, are a pair of conventional spray nozzles 130connected by a flexible tube or conduit 131 and a conventionaladjustable valve 132 to an adhesive-containing reservoir 133. Theadhesive (not shown) within the reservoir 133 is nontoxic, extremelyquick drying, and is preferably controlled in its application throughsuitably adjustably controlling the valve 132 through themicrocontroller Mc in a conventional manner. The spray S emitted fromthe spray nozzles 130 are applied to the opposite longitudinal edges(unnumbered) of the layers L1, L2 and any of the latex particles Lexposed therebetween, as is evident from FIG. 1 of the drawings. Theadhesive will bind all of the exposed latex particles L to each otherand to the longitudinal edges of the layers L1, L2, through preferablyprior to the adhesive drying, the layers L1, L2 and L pass through therollers 17, 18 of the roller compression mechanism or means 16 which arepreferably spring-biased toward each other in a conventional manner orthrough pneumatic fluid cylinders (not shown) to apply desired pressureto the longitudinal edges substantially closing the same incident to theadhesive drying such that the latex L is essentially unexposed afterpassing beyond the rollers 17, 18.

The microcontroller Mc controls the flying cutter or flying shear 22 totransversely cut the completed laminate Lm after the laminate roll Lrhas been formed to a desired length (diameter) followed by wrapping thesame in the packaging material P for shipment to a subsequent user, suchas a mattress manufacturer.

The laminate roll Lr is preferably driven by a right-angled drive 140selectively driven by an electric motor 141 controlled manually by anadjustable rheostat 142 or through the microcontroller Mc. Likeconventional control means 143 (FIG. 1) can be manually adjusted to varythe braking of the roll R1 through the conventional brake 32 or in lieuthereof, the brake 32 can also be controlled by the microcontroller ormicroprocessor Mc.

In lieu of the edge-binding/edge-bonding means 15, the utilization ofconventional stitching heads (not shown) may be provided to sew thelongitudinal edges of layers L1, L2 to each other during the performanceof the lamination process/method.

A walkway W (FIG. 1) preferably traverses the paths of travel P1, P2between the latex depositing mechanism 13 and the support means 12 forthe roll R2 of polyester fiber material M2 or the equivalent. Thewalkway W serves as a substantially central area or location at which anoperator can view the entire laminating machine 10 and the variouscomponents thereof to operate any of the switches or adjusting means 89,142, 143 or the microcontroller Mc, as well as the hand wheel 94 which,though manually rotated, can as well be power driven in a conventionalmanner under the control of the microprocessor or microcontroller Mc.However, whether under a program control from a personal computer (PC)associated with the microcontroller Mc (FIG. 1) or manually, the amountof the latex L deposited upon the layer L1 of polyester fiber materialcan be varied to in turn vary the height H and/or the consistencythrough a variety of adjustments, as, for example:

(1) The driving means 20 can be increased or decreased to respectivelyspeed up or reduce the speed of the layer L2 which, with all otherfactors remaining the same, will respectively decrease and increase theheight H of the latex L.

(2) Obviously, by increasing or decreasing the speed of the motor 87(FIG. 5) the rotation of the vane feeder 81 (FIG. 2) can be varied toagain regulate the height H (FIG. 12) of the latex material L.

(3) Manipulating the pivotable trough plate 72 (FIG. 2) to vary the sizeof the slot 60 will also selectively vary the height H of the latex L1deposited upon the layer L1 (FIG. 12).

(4) Alternating the particular proportioning plate 120, 120′ and 120″and/or the spacer assembly 110 or its vertical height relative to thechute 100 via the vertically offset openings 112 can also be utilized toselectively vary the height H of the latex L deposited upon the layerL1.

Virtually any combination of adjustments (1) through (4) above can beutilized to vary the final end product of the laminate Lm.

A modification of the laminating machine 10 of FIG. 1 is shown in FIG.15 to which attention is now directed, and in this case the modifiedlaminating machine is designated by the reference character 10′ andincludes all of the components of the laminating machine 10 except forthe flying shear or flying cutter 22, and in lieu thereof is substituteda conventional quilting machine Qm having a multiplicity of conventionalquilting heads (Qh) which stitch the laminate Lm immediately uponpassing beyond the rollers 17, 18 of the compressing means 16 and priorto being formed into a roll L′r. The laminate roll L′r is generally fedsimultaneously through the quilting machine Qm upon a web of underlyingcloth material Cm drawn from an associated cloth material roll Cmr. Theindividual stitching or quilting heads Qh of the quilting machine Qm canbe variably adjusted in a conventional manner for quilting any one ofnumerous different stitching patterns or quilting patterns upon thelaminate L′m. However, in keeping with the present invention, thelaminate or laminate material L′m is shown being stitched therethroughwith substantially parallel sinusoidal longitudinal stitching Ls andsubstantially sinusoidal parallel transverse stitching Ts with thestitching Ls and Ts forming individual narrow sinusoidal longitudinalchannels Lc and Tc, respectively, therebetween. At the crossings of thestitching Ls and Ts are formed individual substantially closed pocketsCp with each substantially closed pocket Cp being bounded by portions oftwo of the longitudinal lines of stitching Ls and portions of two of thetransverse lines of stitching Ts. The latter described stitch crossingsnot only define the substantially closed pockets Cp, but the stitchingand closed pockets Cp prevent excessive movement or “migration” of thelatex L from each of the pockets Cp which is highly desirable when thelaminate material L′m is made into a mattress, for example. When, forexample, a portion of the laminate L′m is formed as an upper layer of amattress and a person lies and moves thereupon for days, months or yearsat a time, the latex L will not migrate but instead will remain in eachof the substantially closed pockets Cp and the uniformity andconsistency of the mattress thus manufactured will be maintainedsubstantially for its entire lifetime.

While the closed pockets Cp are a preferable form of the stitching,migration of the latex L of the laminate L′m is substantially lessenedeven absent such “closed” pockets. For example, if the transversestitching Ts were eliminated, the very nature of the narrowness and thesinusoidal curvature of the longitudinal channels Lc would materiallypreclude migration in the longitudinal direction and would, of course,totally preclude migration in the transverse direction. Obviously, theopposite is true, namely, if the longitudinal stitching Ls wereeliminated, the sinusoidal curvature and the narrowness of thetransverse channels Tc would substantially lessen migration of the latexL in the transverse direction and, of course, the transverse stitchingTc would totally preclude migration of the latex L in the longitudinaldirection. Therefore, the stitching of the laminate L′m need only besuch as to define an overall pattern which would substantially lessen orpreclude migration of the latex L between the layers L1, L2,irrespective of the “closed” or “open” nature thereof, throughsubstantially “closed” pockets Cp and equivalents thereof are preferred.

In further accordance with the present invention, the machine 10,through described with respect to utilizing polyester fiber material M1,M2 in association with the respective rolls R1, R2, can be varied inoperation by utilizing other materials, and one particular modificationis illustrated in FIGS. 13 and 14 of the drawings wherein the roll R2 ofpolyester fiber material M2 of FIG. 1 has been eliminated andsubstituted therefor is a roll R′2 of conventional convoluted foam latexmaterial M′2 defined by a relatively flat inner/upper surface S′u and aconvoluted outer lower surface S′1, the latter being defined by aplurality of downwardly/outwardly projecting peaks P′ andoutwardly/downwardly opening valleys V′. Latex particles L′,corresponding to the latex particles L of FIG. 1, are deposited upon anupper surface U′s of a lower layer or web L′1 of polyester fibermaterial M′1 upon which is superimposed a layer or web L′2 drawn fromthe roll R′2 resulting in the valleys V′ being substantially filled withthe pieces of latex L′. Thus, as is best illustrated in FIG. 14, each ofthe valleys V′ defines a substantially closed pocket C′p substantiallyentirely filled by the latex L′ thereby assuring the absence ofmigration thereof, just as in the case of the pockets Cp of FIG. 15, butabsent the quilting thereof. However, the eventually formed laminate L′mcan be stitched utilizing the conventional quilting machine Qm of FIG.15, but the quilting need not be specifically utilized to achievenonmigration of the latex L′.

Although a preferred embodiment of the invention has been specificallyillustrated and described herein, it is to be understood that minorvariations may be made in the apparatus without departing from thespirit and scope of the invention, as defined the appended claims.

What is claimed is:
 1. A method of manufacturing a laminate particularlyadapted for bedding, padding and upholstering comprising the steps offeeding an indeterminate length of a first material along apredetermined first path of travel from a source of the first materialto a downstream assembly area, feeding an indeterminate length of secondmaterial along a predetermined second path of travel from a source ofthe second material to the downstream assembly area, depositing piecesof latex foam of random sizes upon an upper surface of one of the firstand second indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, sandwiching thepieces of latex foam between the indeterminate lengths of first andsecond materials to form a laminate therefrom, rolling the laminate intoa roll, edge-binding longitudinal edges of the laminate, and performingthe edge-binding step by applying an adhesive to a longitudinal edge ofat least one of the first and second indeterminate lengths of material.2. The laminate method as defined in claim 1 including the step ofstitching a plurality of substantially peripherally closedanti-migration pockets solely by a plurality of stitches passingthrough, between and stitching together the first and second materialswithin which pockets substantially all of the pieces of latex foam aresubstantially freely movable while at the same time are substantiallycaptively confined.
 3. A method of manufacturing a laminate particularlyadapted for bedding, padding and upholstering comprising the steps offeeding an indeterminate length of a first material along apredetermined first path of travel from a source of the first materialto a downstream assembly area, feeding an indeterminate length of secondmaterial along a predetermined second path of travel from a source ofthe second material to the downstream assembly area, depositing piecesof latex foam of random sizes upon an upper surface of one of the firstand second indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, sandwiching thepieces of latex foam between the indeterminate lengths of first andsecond materials to form a laminate therefrom, rolling the laminate intoa roll, edge-binding longitudinal edges of the laminate, and performingsaid edge-binding step by spraying an adhesive to a longitudinal edge ofat least one of the first and second indeterminate lengths of material.4. The laminate method as defined in claim 3 including the step ofstitching a plurality of substantially peripherally closedanti-migration pockets solely by a plurality of stitches passingthrough, between and stitching together the first and second materialswithin which pockets substantially all of the pieces of latex foam aresubstantially freely movable while at the same time are substantiallycaptively confined.
 5. A method of manufacturing a laminate particularlyadapted for bedding, padding and upholstering comprising the steps offeeding an indeterminate length of a first material along apredetermined first path of travel from a source of the first materialto a downstream assembly area, feeding an indeterminate length of secondmaterial along a predetermined second path of travel from a source ofthe second material to the downstream assembly area, depositing piecesof latex foam of random sizes upon an upper surface of one of the firstand second indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, sandwiching thepieces of latex foam between the indeterminate lengths of first andsecond materials to form a laminate therefrom, rolling the laminate intoa roll, and stitching a plurality of substantially peripherally closedanti-migration pockets solely by a plurality of stitches passingthrough, between and stitching together the first and second materialswithin which pockets substantially all of the pieces of latex foam aresubstantially freely movable while at the same time are substantiallycaptively confined.
 6. A method of manufacturing a laminate particularlyadapted for bedding, padding and upholstering comprising the steps offeeding an indeterminate length of a first material along apredetermined first path of travel from a source of the first materialto a downstream assembly area, feeding an indeterminate length of secondmaterial along a predetermined second path of travel from a source ofthe second material to the downstream assembly area, depositing piecesof latex foam of random sizes upon an upper surface of one of the firstand second indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, sandwiching thepieces of latex foam between the indeterminate lengths of first andsecond materials to form a laminate therefrom, rolling the laminate intoa roll, creating a plurality of downwardly opening valleys in a lowersurface of the other of the first and second indeterminate lengths ofmaterial which substantially house the pieces of latex foam thereinincident to performing the sandwiching step.
 7. A method ofmanufacturing a laminate particularly adapted for bedding, padding andupholstering comprising the steps of feeding an indeterminate length ofa first material along a predetermined first path of travel from asource of the first material to a downstream assembly area, feeding anindeterminate length of second material along a predetermined secondpath of travel from a source of the second material to the downstreamassembly area, depositing pieces of latex foam of random sizes upon anupper surface of one of the first and second indeterminate lengths ofmaterial during the feeding thereof between the respective sources andthe assembly area, sandwiching the pieces of latex foam between theindeterminate lengths of first and second materials to form a laminatetherefrom, rolling the laminate into a roll, the depositing step iseffected from a trough housing a supply of the pieces of latex foam, thetrough being in substantially transverse spanning relationship to thefeeding direction of the first material, the trough includes openingsthrough which pass the pieces of latex foam incident to the performanceof the depositing step, and removing the trough openings and replacingthe trough openings with different trough openings to therebyselectively vary the deposition of the pieces of latex foam upon thefirst material.
 8. The laminate method as defined in claim 7 includingthe step of stitching a plurality of substantially peripherally closedanti-migration pockets solely by a plurality of stitches passingthrough, between and stitching together the first and second materialswithin which pockets substantially all of the pieces of latex foam aresubstantially freely movable while at the same time are substantiallycaptively confined.
 9. A method of manufacturing a laminate particularlyadapted for bedding, padding and upholstering comprising the steps offeeding an indeterminate length of a first material along apredetermined first path of travel from a source of the first materialto a downstream assembly area, feeding an indeterminate length of secondmaterial along a predetermined second path of travel from a source ofthe second material to the downstream assembly area, depositing piecesof latex foam of random sizes upon an upper surface of one of the firstand second indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, sandwiching thepieces of latex foam between the indeterminate lengths of first andsecond materials to form a laminate therefrom, rolling the laminate intoa roll, the depositing step is effected from a trough housing a supplyof the pieces of latex foam, the trough being in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial, the trough includes opening through which pass the pieces oflatex foam incident to the performance of the depositing step,selectively varying the size of the trough opening, the trough openingbeing a slot extending substantially along the length of said trough,and selectively adjusting the transverse dimension of the slot tothereby regulate the deposition of the pieces of latex foam upon thefirst material.
 10. The laminate method as defined in claim 9 includingthe step of stitching a plurality of substantially peripherally-closedanti-migration pockets solely by a plurality of stitches passingthrough, between and stitching together the first and second materialswithin which pockets substantially all of the pieces of latex foam aresubstantially freely movable while at the same time are substantiallycaptively confined.
 11. A method of manufacturing a laminateparticularly adapted for bedding, padding and upholstering comprisingthe steps of feeding an indeterminate length of a first material along apredetermined first path of travel from a source of the first materialto a downstream assembly area, feeding an indeterminate length of secondmaterial along a predetermined second path of travel from a source ofthe second material to the downstream assembly area, depositing piecesof latex foam of random sizes an upper surface of one of the first andsecond indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, sandwiching thepieces of latex foam between the indeterminate lengths of first andsecond materials to form a laminate therefrom, quilting the laminate,and stitching a plurality of substantially peripherally closedanti-migration pockets solely by a plurality of stitches passingthrough, between and stitching together the first and second materialswithin which pockets substantially all of the pieces of latex foam aresubstantially freely movable while at the same time are substantiallycaptively confined.
 12. A method of manufacturing a laminateparticularly adapted for bedding, padding and upholstering comprisingthe steps of feeding an indeterminate length of first material havingopposite surfaces along a predetermined first path of travel from asource of the first material to a downstream assembly area, feeding anindeterminate length of second material having opposite surfaces along apredetermined second path of travel from a source of the second materialto the assembly area, depositing pieces of latex foam of random sizesupon an upper surface of one of the first and second indeterminatelength material during the feeding thereof between the respectivesources and the assembly area prior to sandwiching the pieces of latexfoam between the upper surface of the one material and a lower surfaceof another of the first and second indeterminate length materials, atleast one of the upper and lower surfaces being a convoluted surfacedefined by peaks and valleys, and sandwiching the pieces of latex foambetween the indeterminate lengths of first and second materials to forma laminate therefrom and during the sandwiching of the first and secondmaterials confining the pieces of latex foam in the valleys.
 13. Thelaminating method as defined in claim 12 wherein the indeterminatelength material having the convoluted surface is latex.
 14. Thelaminating method as defined in claim 12 wherein the convoluted surfaceis the lower surface.
 15. The laminating method as defined in claim 12wherein the convoluted surface is the upper surface.
 16. The laminatingmethod as defined in claim 12 wherein the convoluted surface is thelower surface of an uppermost of the first and second indeterminatelength materials.
 17. The laminating method as defined in claim 16wherein the indeterminate length material having the convoluted surfaceis latex.
 18. The laminating method as defined in claim 12 wherein theconvoluted surface is the upper surface of a lowermost of the first andsecond indeterminate length materials.
 19. The laminating method asdefined in claim 12 wherein the convoluted surface is the lower surfaceof an uppermost of the first and second indeterminate length materials,and the upper surface is a substantially planar surface of a lowermostof the first and second indeterminate length materials.
 20. Thelaminating method as defined in claim 12 wherein the convoluted surfaceis the upper surface of a lowermost of the first and secondindeterminate length materials, and the lower surface is a substantiallyplanar surface of an uppermost of the first and second indeterminatelength materials.
 21. The laminating method as defined in claim 20wherein the indeterminate length material having the convoluted surfaceis latex, and the cushioning materials are latex.
 22. The laminatingmethod as defined in claim 12 wherein the convoluted surface is thelower surface of an uppermost of the first and second indeterminatelength materials, the upper surface is a substantially planar surface ofa lowermost of the first and second indeterminate length materials, andcrest portions of the peaks contact the planar surface.
 23. Thelaminating method as defined in claim 22 wherein the indeterminatelength material having the convoluted surface is latex.
 24. Thelaminating method as defined in claim 12 wherein the convoluted surfaceis the upper surface of a lowermost of the first and secondindeterminate length materials, the lower surface is a substantiallyplanar surface of an uppermost of the first and second indeterminatelength materials, and crest portions of the peaks contact the planarsurface.
 25. The laminating method as defined in claim 12 wherein thevolume of pieces of latex foam deposited upon the upper surface issubstantially confined in the valleys.
 26. The laminating method asdefined in claim 12 including the step of edge-binding longitudinaledges of the laminate.
 27. The laminating method as defined in claim 12including the step of edge-bonding longitudinal edges of the laminate.28. The laminating method as defined in claim 12 including the step ofrolling the laminate into a roll.
 29. A method of manufacturing alaminate particularly adapted for bedding, padding and upholsteringcomprising the steps of feeding an indeterminate length of firstmaterial having opposite surfaces along a predetermined first path oftravel from a source of the first material to a downstream assemblyarea, feeding an indeterminate length of second material having oppositesurfaces along a predetermined second path of travel from a source ofthe second material to the assembly area, depositing pieces of latexfoam of random sizes upon an upper surface of one of the first andsecond indeterminate length materials during the feeding thereof betweenthe respective sources and the assembly area prior to sandwiching thepieces of latex foam between the upper surface of the one material and alower surface of another of the first and second indeterminate lengthmaterials, the volume of pieces of latex foam deposited upon the uppersurface is substantially in the range of 0.15-0.50 pound per squareyard, and one of the indeterminate length materials is latex and anotherof the indeterminate length materials is polyester fiber.
 30. A methodof manufacturing a laminate particularly adapted for bedding, paddingand upholstering comprising the steps of feeding an indeterminate lengthof first material having opposite surfaces along a predetermined firstpath of travel from a source of the first material to a downstreamassembly area, feeding an indeterminate length of second material havingopposite surfaces along a predetermined second path of travel from asource of the second material to the assembly area, depositing pieces oflatex foam of random sizes upon an upper surface of one of the first andsecond indeterminate length materials during the feeding thereof betweenthe respective sources and the assembly area prior to sandwiching thepieces of latex foam between the upper surface of the one material and alower surface of another of the first and second indeterminate lengthmaterials, the volume of pieces of latex foam deposited upon the uppersurface is substantially in the range of 0.15-0.50 pound per squareyard, one of the indeterminate length materials is latex and another ofthe indeterminate length materials is polyester fiber, the oneindeterminate length material includes a convoluted surface defined bypeaks and valleys, and the pieces of latex foam are housed in thevalleys.
 31. A method of manufacturing a laminate particularly adaptedfor bedding, padding and upholstering comprising the steps of feeding anindeterminate length of first material having opposite surfaces along apredetermined first path of travel from a source of the first materialto a downstream assembly area, feeding an indeterminate length of secondmaterial having opposite surfaces along a predetermined second path oftravel from a source of the second material to the assembly area,depositing pieces of latex foam of random sizes upon an upper surface ofone of the first and second indeterminate length materials during thefeeding thereof between the respective sources and the assembly areaprior to sandwiching the pieces of latex foam between the upper surfaceof the one material and a lower surface of another of the first andsecond indeterminate length materials, and stitching a plurality ofsubstantially peripherally closed anti-migration pockets solely by aplurality of stitches passing through, between and stitching togetherthe first and second materials within which pockets substantially all ofthe pieces of latex foam are substantially freely movable while at thesame time are substantially captively confined.
 32. The laminatingmethod as defined in claim 31 wherein the stitched anti-migratory areasare substantially pockets.
 33. The laminating method as defined in claim31 wherein the stitched anti-migratory areas are substantially closedpockets.
 34. The laminating method as defined in claim 31 wherein thestitched anti-migratory areas are substantially narrow channels.
 35. Thelaminating method as defined in claim 31 wherein the stitchedanti-migratory areas are substantially narrow crossing channels.
 36. Thelaminating method as defined in claim 31 wherein the stitchedanti-migratory areas are substantially narrow sinusoidal channels.
 37. Amethod of manufacturing a laminate particularly adapted for bedding,padding and upholstering comprising the steps of feeding anindeterminate length of a first material along a predetermined firstpath of travel from a source of the first material to a downstreamassembly area, feeding an indeterminate length of second material alonga predetermined second path of travel from a source of the secondmaterial to the downstream assembly area, depositing pieces of latexfoam of random sizes upon an upper surface of one of the first andsecond indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, sandwiching thepieces of latex foam between the indeterminate lengths of first andsecond materials to form a laminate therefrom, and stitching a pluralityof substantially peripherally closed anti-migration pockets solely by aplurality of stitches passing through, between and stitching togetherthe first and second materials within which pockets substantially all ofthe pieces of latex foam are substantially freely movable while at thesame time are substantially captively confined.
 38. The method asdefined in claim 37 including the steps of edge-binding longitudinaledges of the laminate.
 39. The method as defined in claim 37 includingthe steps of edge-bonding longitudinal edges of the laminate.
 40. Themethod as defined in claim 37 including the step of selectively varyingthe speed of the first material during the feeding thereof along thefirst path of travel.
 41. The method as defined in claim 37 includingthe step of varying the depositing of the pieces of latex foam.
 42. Themethod as defined in claim 37 including the step of varying thedepositing of the pieces of latex foam in correlation with the variationin speed of the fire material.
 43. A machine for manufacturing alaminate particularly adapted for bedding, padding and upholsteringcomprising first means for feeding an indeterminate length of a firstmaterial along a predetermined first path of travel from a source of thefirst material to a downstream assembly area, second means for feedingan indeterminate length of second material along a predetermined secondpath of travel from a source of the second material to the downstreamassembly area, means for depositing a multiplicity of pieces of foamlatex of random sizes upon an upper surface of one of the first andsecond indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, means forsandwiching the pieces of foam latex between the indeterminate lengthsof first and second materials to form a laminate therefrom, means forrolling the laminate into a roll, means for edge-binding longitudinaledges of the laminate, and said edge-binding means includes means forapplying an adhesive to a longitudinal edge of at least one of the firstand second indeterminate lengths of material.
 44. The laminatemanufacturing machine as defined in claim 43 including means forcompressing the laminate longitudinal edges.
 45. The machine as definedin claim 43 wherein the edge-bonding means includes means forcompressing the laminate.
 46. The machine as defined in claim 43 whereinthe edge-bonding means includes means for compressing the laminateedges.
 47. The machine as defined in claim 43 wherein the edge-bondingmeans includes means for compressing the laminate edges upstream of saidrolling means.
 48. The laminate manufacturing machine as defined inclaim 43 including stitching means for solely forming a plurality ofsubstantially peripherally closed anti-migration areas for substantiallycaptively housing the pieces of latex foam between the first and secondmaterials, and said stitching means are a plurality of stitches passingthrough and stitching together the first and second materials into saidsubstantially peripherally closed anti-migration areas within which allpieces of foam are substantially confined yet are substantially free tomove.
 49. A machine for manufacturing a laminate particularly adaptedfor bedding, padding and upholstering comprising first means for feedingan indeterminate length of a first material along a predetermined firstpath of travel from a source of the first material to a downstreamassembly area, second means for feeding an indeterminate length ofsecond material along a predetermined second path of travel from asource of the second material to the downstream assembly area, means fordepositing a multiplicity of pieces of foam latex of random sizes uponan upper surface of one of the first and second indeterminate lengths ofmaterial during the feeding thereof between the respective sources andthe assembly area, means for sandwiching the pieces of foam latexbetween the indeterminate lengths of first and second materials to forma laminate therefrom, means for rolling the laminate into a roll, meansfor edge-binding longitudinal edges of the laminate, and saidedge-binding means includes means for spraying an adhesive to alongitudinal edge of at least one of the first and second indeterminatelengths of material.
 50. The laminate manufacturing machine as definedin claim 49 including stitching means for solely forming a plurality ofsubstantially peripherally closed anti-migration areas for substantiallycaptively housing the pieces of latex foam between the first and secondmaterials, and said stitching means are a plurality of stitches passingthrough and stitching together the first and second materials into saidsubstantially peripherally closed anti-migration areas within which allpieces of foam are substantially confined yet are substantially free tomove.
 51. A machine for manufacturing a laminate particularly adaptedfor bedding, padding and upholstering comprising first means for feedingan indeterminate length of a first material along a predetermined firstpath of travel from a source of the first material to a downstreamassembly area, second means for feeding an indeterminate length ofsecond material along a predetermined second path of travel from asource of the second material to the downstream assembly area, means fordepositing a multiplicity of pieces of foam latex of random sizes uponan upper surface of one of the first and second indeterminate lengths ofmaterial during the feeding thereof between the respective sources andthe assembly area, means for sandwiching the pieces of foam latexbetween the indeterminate lengths of first and second materials to forma laminate therefrom, stitching means for solely forming a plurality ofsubstantially peripherally closed anti-migration areas for substantiallycaptively housing the pieces of latex foam between the first and secondmaterials, and said stitching means are a plurality of stitches passingthrough and stitching together the first and second materials into saidsubstantially peripherally closed anti-migration areas within whichsubstantially all pieces of foam latex are substantially free to move.52. A machine for manufacturing a laminate particularly adapted forbedding, padding and upholstering comprising first means for feeding anindeterminate length of a first material along a predetermined firstpath of travel from a source of the first material to a downstreamassembly area, second means for feeding an indeterminate length ofsecond material along a predetermined second path of travel from asource of the second material to the downstream assembly area, means fordepositing a multiplicity of pieces of foam latex of random sizes uponan upper surface of one of the first and second indeterminate lengths ofmaterial during the feeding thereof between the respective sources andthe assembly area, means for sandwiching the pieces of foam latexbetween the indeterminate lengths of first and second materials to forma laminate therefrom, means for rolling the laminate into a roll, thedepositing means including trough means for housing a supply of thepieces of latex foam, said trough means being in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial, opening means along said trough means through which pass thepieces of latex foam incident to the depositing thereof upon the firstmaterial, said opening means being a slot extending substantially alongthe length of said trough means, and means for selectively adjusting thetransverse dimension of said slot to thereby regulate the deposition ofthe pieces of latex foam upon the first material.
 53. The laminatemanufacturing machine as defined in claim 52 including stitching meansfor solely forming a plurality of substantially peripherally closedanti-migration areas for substantially captively housing the pieces oflatex foam between the first and second materials, and said stitchingmeans are a plurality of stitches passing through and stitching togetherthe first and second materials into said substantially peripherallyclosed anti-migration areas within which all pieces of foam aresubstantially confined yet are substantially free to move.
 54. A machinefor manufacturing a laminate particularly adapted for bedding, paddingand upholstering comprising first means for feeding an indeterminatelength of a first material along a predetermined first path of travelfrom a source of the first material to a downstream assembly area,second means for feeding an indeterminate length of second materialalong a predetermined second path of travel from a source of the secondmaterial to the downstream assembly area, means for depositing amultiplicity of pieces of foam latex of random sizes upon an uppersurface of one of the first and second indeterminate lengths of materialduring the feeding thereof between the respective sources and theassembly area, means for sandwiching the pieces of foam latex betweenthe indeterminate lengths of first and second materials to form alaminate therefrom, means for rolling the laminate into a roll thedepositing means including trough means for housing a supply of thepieces of latex foam, said trough means being in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial, opening means along said trough means through which pass thepieces of latex foam incident to the depositing thereof upon the firstmaterial, said opening means being a slot extending substantially alongthe length of said trough means, means for selectively adjusting thetransverse dimension of said slot to thereby regulate the deposition ofthe pieces of latex foam upon the first material, said slot beingdefined in part by a movable trough plate having a lower edge in partdefining said slot, and said adjusting means includes means for movingsaid trough plate and its lower edge to thereby adjust the transversedimension of said slot.
 55. The laminate manufacturing machine asdefined in claim 54 including stitching means for solely forming aplurality of substantially peripherally closed anti-migration areas forsubstantially captively housing the pieces of latex foam between thefirst and second materials, and said stitching means are a plurality ofstitches passing through and stitching together the first and secondmaterials into said substantially peripherally closed anti-migrationareas within which all pieces of foam are substantially confined yet aresubstantially free to move.
 56. A machine for manufacturing a laminateparticularly adapted for bedding, padding, and upholstering comprisingfirst means for feeding an indeterminate length of a first materialalong a predetermined first path of travel from a source of the firstmaterial to a downstream assembly area, second means for feeding anindeterminate length of second material along a predetermined secondpath of travel from a source of the second material to the downstreamassembly area, means for depositing a multiplicity of pieces of foamlatex of random sizes upon an upper surface of one of the first andsecond indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, means forsandwiching the pieces of foam latex between the indeterminate lengthsof first and second materials to form a laminate therefrom, means forrolling the laminate into a roll, the depositing means including troughmeans for housing a supply of the pieces of latex foam, said troughmeans being in substantially transverse spanning relationship to thefeeding direction of the first material, opening means along said troughmeans through which pass the pieces of latex foam incident to thedepositing thereof upon the first material, said opening means being aslot extending substantially along the length of said trough means,means for selectively adjusting the transverse dimension of said slot tothereby regulate the deposition of the pieces of latex foam upon thefirst material, said slot being defined in part by a pivotable troughplate having a lower edge in part defining said slot, and said adjustingmeans includes means for pivoting said trough plate and its lower edgeto thereby adjust the transverse dimension of said slot.
 57. Thelaminate manufacturing machine as defined in claim 56 includingstitching means for solely forming a plurality of substantiallyperipherally closed anti-migration areas for substantially captivelyhousing the pieces of latex foam between the first and second materials,and said stitching means are a plurality of stitches passing through andstitching together the first and second materials into saidsubstantially peripherally closed anti-migration areas within which allpieces of foam are substantially confined yet are substantially free tomove.
 58. A machine for manufacturing a laminate particularly adaptedfor bedding, padding and upholstering comprising first means for feedingan indeterminate length of a first material along a predetermined firstpath of travel from a source of the first material to a downstreamassembly area, second means for feeding an indeterminate length ofsecond material along a predetermined second path of travel from asource of the second material to the downstream assembly area, means fordepositing a multiplicity of pieces of foam latex of random sizes uponan upper surface of one of the first and second indeterminate lengths ofmaterial during the feeding thereof between the respective sources andthe assembly area, means for sandwiching the pieces of foam latexbetween the indeterminate lengths of first and second materials to forma laminate therefrom, means for rolling the laminate into a roll, thedepositing means including trough means for housing a supply of thepieces of latex foam, said trough means being in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial, opening means along said trough means through which pass thepieces of latex foam incident to the depositing thereof upon the firstmaterial, said opening means being a slot extending substantially alongthe length of said trough means, means for selectively adjusting thetransverse dimension of said slot to thereby regulate the deposition ofthe pieces of latex foam upon the first material, and rotatable feedmeans for regulating the passage of the pieces of latex foam through theslot.
 59. The laminate manufacturing machine as defined in claim 58including stitching means for solely forming a plurality ofsubstantially peripherally closed anti-migration areas for substantiallycaptively housing the pieces of latex foam between the first and secondmaterials, and said stitching means are a plurality of stitches passingthrough and stitching together the first and second materials into saidsubstantially peripherally closed anti-migration areas within which allpieces of foam are substantially confined yet are substantially free tomove.
 60. A machine for manufacturing a laminate particularly adaptedfor bedding, padding and upholstering comprising first means for feedingan indeterminate length of a first material along a predetermined firstpath of travel from a source of the first material to a downstreamassembly area, second means for feeding an indeterminate length ofsecond material along a predetermined second path of travel from asource of the second material to the downstream assembly area, means fordepositing a multiplicity of pieces of foam latex of random sizes uponan upper surface of one of the first and second indeterminate lengths ofmaterial during the feeding thereof between the respective sources andthe assembly area means for sandwiching the pieces of foam latex betweenthe indeterminate lengths of first and second materials to form alaminate therefrom, means for rolling the laminate into a roll, thedepositing means including trough means for housing a supply of thepieces of latex foam, said trough means being in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial, opening means along said trough means through which pass thepieces of latex foam incident to the depositing thereof upon the firstmaterial, said opening means being a slot extending substantially alongthe length of said trough means, means for selectively adjusting thetransverse dimension of said slot to thereby regulate the deposition ofthe pieces of latex foam upon the first material, said slot beingdefined in part by a pivotable trough plate having a lower edge in partdefining said slot, said adjusting means includes means for pivotingsaid trough plate and its lower edge to thereby adjust the transversedimension of said slot, and rotatable feed means for regulating thepassage of the pieces of latex foam through the slot.
 61. The laminatemanufacturing machine as defined in claim 60 including stitching meansfor solely forming a plurality of substantially peripherally closedanti-migration areas for substantially captively housing the pieces oflatex foam between the first and second materials, and said stitchingmeans are a plurality of stitches passing through and stitching togetherthe first and second materials into said substantially peripherallyclosed anti-migration areas within which all pieces of foam aresubstantially confined yet are substantially free to move.
 62. A machinefor manufacturing a laminate particularly adapted for bedding, paddingand upholstering comprising first means for feeding an indeterminatelength of a first material along a predetermined first path of travelfrom a source of the first material to a downstream assembly area secondmeans for feeding an indeterminate length of second material along apredetermined second path of travel from a source of the second materialto the downstream assembly area, means for depositing a multiplicity ofpieces of foam latex of random sizes upon an upper surface of one of thefirst and second indeterminate lengths of material during the feedingthereof between the respective sources and the assembly area, means forsandwiching the pieces of foam latex between the indeterminate lengthsof first and second materials to form a laminate therefrom, means forrolling the laminate into a roll, the depositing means includes a troughdisposed in substantially transverse spanning relationship to thefeeding direction of the first material, opening means along a bottom ofsaid trough through which pass the pieces of latex foam incident to thedepositing thereof upon the first material, a chute substantiallysurrounding said opening means and extending downwardly toward the firstmaterial, a lower terminal edge of said chute being spaced slightlyabove the first material, and means for maintaining a space between saidchute terminal edge and the first material.
 63. The laminatemanufacturing machine as defined in claim 62 including stitching meansfor solely forming a plurality of substantially peripherally closedanti-migration areas for substantially captively housing the pieces oflatex foam between the first and second materials, and said stitchingmeans are a plurality of stitches passing through and stitching togetherthe first and second materials into said substantially peripherallyclosed anti-nonmigration areas within which all pieces of foam aresubstantially confined yet are substantially free to move.
 64. A machinefor manufacturing a laminate particularly adapted for bedding, paddingand upholstering comprising first means for feeding an indeterminatelength of a first material along a predetermined first path of travelfrom a source of the first material to a downstream assembly area,second means for feeding an indeterminate length of second materialalong a predetermined second path of travel from a source of the secondmaterial to the downstream assembly area, means for depositing amultiplicity of pieces of foam latex of random sizes upon an uppersurface of one of the first and second indeterminate lengths of materialduring the feeding thereof between the respective sources and theassembly area, means for sandwiching the pieces of foam latex betweenthe indeterminate lengths of first and second materials to form alaminate therefrom, means for rolling the laminate into a roll, meansfor edge-binding longitudinal edges of the laminate, and the depositingmeans includes trough means for housing a supply of the pieces of latexfoam, said trough means being in substantially transverse spanningrelationship to the feeding direction of the first material, openingmeans along said trough means through which pass the pieces of latexfoam incident to the depositing thereof upon the first material, saidopening means being a slot extending substantially along the length ofsaid trough means, means for selectively adjusting the transversedimension of said slot to thereby regulate the deposition of the piecesof latex foam upon the first material, said slot being defined in partby a movable trough plate having a lower edge in part defining saidslot, and said adjusting means includes means for moving said troughplate and its lower edge to thereby adjust the transverse dimension ofsaid slot.
 65. A machine for manufacturing a laminate particularlyadapted for bedding, padding and upholstering comprising first means forfeeding an indeterminate length of a first material along apredetermined first path of travel from a source of the first materialto a downstream assembly area, second means for feeding an indeterminatelength of second material along a predetermined second path of travelfrom a source of the second material to the downstream assembly area,means for depositing a multiplicity of pieces of foam latex of randomsizes upon an upper surface of one of the first and second indeterminatelengths of material during the feeding thereof between the respectivesources and the assembly area, means for sandwiching the pieces of foamlatex between the indeterminate lengths of first and second materials toform a laminate therefrom, means for rolling the laminate into a roll,means for edge-binding longitudinal edges of the laminate, and thedepositing means includes trough means for housing a supply of thepieces of latex foam, said trough means being in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial, opening means along said trough means through which pass thepieces of latex foam incident to the depositing thereof upon the firstmaterial, said opening means being a slot extending substantially alongthe length of said trough means, means for selectively adjusting thetransverse dimension of said slot to thereby regulate the deposition ofthe pieces of latex foam upon the first material, said slot beingdefined in part by a pivotable trough plate having a lower edge in partdefining said slot, and said adjusting means includes means for pivotingsaid trough plate and its lower edge to thereby adjust the transversedimension of said slot.
 66. A machine for manufacturing a laminateparticularly adapted for bedding, padding and upholstering comprisingfirst means for feeding an indeterminate length of a first materialalong a predetermined first path of travel from a source of the firstmaterial to a downstream assembly area, second means for feeding anindeterminate length of second material along a predetermined secondpath of travel from a source of the second material to the downstreamassembly area, means for depositing a multiplicity of pieces of foamlatex of random sizes upon an upper surface of one of the first andsecond indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, means forsandwiching the pieces of foam latex between the indeterminate lengthsof first and second materials to form a laminate therefrom, means forrolling the laminate into a roll, means for edge-binding longitudinaledges of the laminate, and the depositing means includes trough meansfor housing a supply of the pieces of latex foam, said trough meansbeing in substantially transverse spanning relationship to the feedingdirection of the first material, opening means along said trough meansthrough which pass the pieces of latex foam incident to the depositingthereof upon the first material, said opening means being a slotextending substantially along the length of said trough means, means forselectively adjusting the transverse dimension of said slot to therebyregulate the deposition of the pieces of latex foam upon the firstmaterial, and rotatable feed means for regulating the passage of thepieces of latex foam through the slot.
 67. A machine for manufacturing alaminate particularly adapted for bedding, padding and upholsteringcomprising first means for feeding an indeterminate length of a firstmaterial along a predetermined first path of travel from a source of thefirst material to a downstream assembly area, second means for feedingan indeterminate length of second material along a predetermined secondpath of travel from a source of the second material to the downstreamassembly area, means for depositing a multiplicity of pieces of foamlatex of random sizes upon an upper surface of one of the first andsecond indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, means forsandwiching the pieces of foam latex between the indeterminate lengthsof first and second materials to form a laminate therefrom, thedepositing means including trough means for housing a supply of thepieces of latex foam; said trough means being in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial and above the first material during the feeding thereof;opening means along said trough means through which pass the pieces oflatex foam incident to the gravity depositing thereof upon the firstmaterial, said opening means being a slot extending substantially alongthe length of said trough means, means for selectively adjusting thetransverse dimension of said slot to thereby regulate the deposition ofthe pieces of latex foam upon the first material, and means forimparting motion to the pieces of latex foam to augment the gravitydeposition thereof upon the first material.
 68. The machine as definedin claim 67 including means for rolling the laminate into a roll, andmeans for drivingly rotating said laminate rolling means to therebyautomatically draw the first and second materials toward the assemblyarea.
 69. The machine as defined in claim 68 including means forselectively controlling the drivingly rotating means and the, latex foampieces motion imparting means to achieve a desired height of deposit ofthe latex foam pieces upon the first material.
 70. The machine asdefined in claim 68 including means for selectively varying the speed ofsaid drive means.
 71. A machine for manufacturing a laminateparticularly adapted for bedding, padding and upholstering comprisingfirst means for feeding an indeterminate length of a first materialalong a predetermined first path of travel from a source of the firstmaterial to a downstream assembly area, second means for feeding anindeterminate length of second material along a predetermined secondpath of travel from a source of the second material to the downstreamassembly area, means for depositing a multiplicity of pieces of foamlatex of random sizes upon an upper surface of one of the first andsecond indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, means forsandwiching the pieces of foam latex between the indeterminate lengthsof first and second materials to form a laminate therefrom, thedepositing mans including opening means through which pass the pieces oflatex foam incident to the depositing thereof upon the first material,said opening means being in substantially transverse spanningrelationship to the feeding direction of the first material, and saidopening means including at least a first opening of a first sizediffering from a second opening of a second size whereby at least twodifferent zones of the foam latex pieces are deposited upon the firstmaterial.
 72. The machine for manufacturing a laminate as defined inclaim 71 wherein a plurality of said first openings are disposedtransversely along and adjacent a first longitudinal edge of the firstmaterial, and a plurality of said second openings are disposedtransversely along and adjacent a second longitudinal edge of the firstmaterial.
 73. The machine for manufacturing a laminate as defined inclaim 71 wherein a plurality of said first and second openings aredisposed transversely along and adjacent first and second oppositelongitudinal edges of the first material.
 74. The machine formanufacturing a laminate as defined in claim 71 wherein a plurality ofsaid first and second openings are disposed transversely substantiallyentirely across the first material.